Construction system including perforated modular structural members

ABSTRACT

A construction system includes three types of structural members. The first type includes a first flange and a second flange merged at a right angle. The first flange includes a row of circular apertures extending longitudinally between the first end and the second end, a first oblong aperture and a second oblong aperture. The second flange includes a row of circular apertures extending longitudinally between the first end and the second end. The second type includes a single flange with a row of circular apertures, a first oblong aperture and a second oblong aperture. The third type includes a first flange and a second flange merged at a right angle with at least one closed end. The first flange includes a row of circular apertures, a first oblong aperture and a second oblong aperture. The second flange includes a row of circular apertures. The structural members may be joined to form a structure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates, in general, to a construction system and, more particularly, to a construction system that utilizes pre-manufactured perforated modular structural members.

2. Description of Related Art

Various constructional elements and systems are known in the art. For instance, U.S. Pat. No. 5,802,780 to Hammerschlag describes a construction system including structural members with premanufactured rows of holes. The system includes three different types of structural members that are a variety of sizes. The first type, referred to as posts, includes two lengthwise rows of holes through the sides. The holes of one row perpendicularly intersect the holes of the other row. The second type, referred to as beams, includes a single lengthwise row of holes through the side. The final type, referred to as diagonals, include holes that are equally spaced and are intended to brace structures. The three types of structural members can be used in combination to construct various types of structures including shelves, tables, and the like. However, the construction system described in the Hammershclag patent requires a variety of different fasteners thereby creating some difficulty during construction.

U.S. Pat. Nos. 3,969,867; 3,003,600; and 2,632,533, each to MacKenzie describe constructional elements with an L-shaped cross-section formed by two metal flanges joined at a right angle. Each flange includes at least one row of regularly-spaced holes extending longitudinally thereon. The holes are both circular and non-circular. The constructional elements may be configured to form a variety of structural units and frameworks. The constructional elements of the MacKenzie patents require a complex series of holes with different shapes and are, therefore, difficult and time consuming to manufacture.

U.S. Pat. No. 3,648,426 to Chaudhary describes an elongated L-shaped metallic constructional element including a pair of angularly disposed flanges with at least one row of holes in each flange. The holes may be different sizes and shapes, including circular and oblong, and the flanges may be of the same or different widths and can contain one or several rows of holes. The constructional elements may be configured to form frameworks, racks, partitions, and other like structures. The constructional elements of the Chaudhary patent also require a somewhat complex series of holes with different shapes.

Accordingly, a need exists for a construction system that includes structural members that are precut to a variety of lengths and include a simple series of perforations thereby allowing the structural members to be easily and quickly assembled to form a desired structure.

SUMMARY OF THE INVENTION

The present invention is directed to a construction system including perforated modular structural members. The construction system includes three types of structural members.

A first type of structural member includes a first flange and a second flange merged at a right angle. Each flange has a first end and a second end. The first flange includes a row of circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end. The second flange includes a row of circular apertures extending longitudinally between the first end and the second end.

A second type of structural member includes a single flange having a first end and a second end with a row of circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end.

A third type of structural member includes a first flange and a second flange, each with a first end and a second end, merged at a right angle. At least one of the first end and second end is closed by a web perpendicular to both flanges. The first flange includes a row of circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end. The second flange includes a row of circular apertures extending longitudinally between the first end and the second end. The web may also include an aperture.

The structural members of the first type, the second type, and the third type are joinable together using fastening members passed through the circular and oblong apertures to form a structure. The oblong apertures may be arranged perpendicular to each other.

The structure may be shelves, tool racks, window boxes, animal pens, or floor stands. The fastening members may be bolts and nuts, sheet metal screws, toggle bolts, masonry anchors, or wood screws or the like.

The oblong apertures in each type of structural member are essential so as to provided nesting of the members when assembled.

These and other features and characteristics of the present invention will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an elevated top view of a first type of modular perforated structural members in accordance with the present invention;

FIG. 1B is a perspective view of one of the structural members of FIG. 1A;

FIG. 2 is an elevated top view of a second type of modular perforated structural members in accordance with the present invention;

FIG. 3A is an elevated top view of a third type of modular perforated structural members in accordance with the present invention;

FIG. 3B is a perspective view of one of the structural members of FIG. 3A;

FIGS. 4A-4D are perspective views of different structures formed from the modular perforated structural members in accordance with the present invention; and

FIGS. 5A-5C are perspective views of additional uses for the modular perforated structural members in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a construction system utilizing modular perforated structural members. The construction system includes three different types of structural members that are precut to various lengths and include a plurality of apertures.

With reference to FIGS. 1A and 1B, a first type of structural member 3, 5, 7, 9, 11, 13, and 15 includes a first flange 17 and a second flange 19. First flange 17 and second flange 19 are merged at a right angle to form an L-shape. First flange 17 has a first end 21 and a second end 23 and a plurality of spaced circular apertures 25 extending longitudinally between first end 21 and second end 23. Desirably, each of the circular apertures are spaced an equal distance N apart. First flange 17 further includes a first oblong aperture 27 located at first end 21 of first flange 17, and a second oblong aperture 29 located at second end 23 of first flange 17. First oblong aperture 27 is positioned so as to be perpendicular to second oblong aperture 29. Due to the thickness of the material used to form the structural members, circular apertures 25 do not always allow for a smooth fit between two structural members when a fastening member is positioned through the apertures. Therefore, oblong apertures 27 and 29 are provided to allow for a smooth fit when two structural members are connected to each other via a fastening member.

Second flange 19 includes a first end 31 and a second end 33 with a plurality of circular apertures 35 extending longitudinal between ends 31 and 33. Each of the circular apertures are spaced an equal distance N apart.

The first type of structural member 3, 5, 7, 9, 11, 13, and 15 may be formed from any suitable material including, but not limited to, steel, aluminum, copper, and the like.

Although FIG. 1A shows seven different lengths of the first type of structural members 3, 5, 7, 9, 11, 13, and 15, this is not to be construed as limiting the present invention as both longer and shorter lengths have been envisioned.

With reference to FIG. 2, a second type of structural member 37, 39, 41, 43, 45, 47, and 49 comprises a single flange 51 with a first end 53 and a second end 55. Single flange 51 includes a plurality of circular apertures 57 extending between ends 53 and 55. Each of the circular apertures are spaced an equal distance N apart. Single flange 51 further includes a first oblong aperture 59 located at first end 53 of single flange 51, and a second oblong aperture 61 located at second end 55 of single flange 51. First oblong aperture 59 is positioned so as to be perpendicular to second oblong aperture 61.

The second type of structural member 37, 39, 41, 43, 45, 47 and 49 may also be formed from any suitable material including, but not limited to, steel, aluminum, copper and the like.

Although FIG. 2 shows seven different lengths of the first type of structural member 37, 39, 41, 43, 45, 47, and 49, this is not to be construed as limiting the present invention as both longer and shorter lengths have been envisioned.

With reference to FIGS. 3A and 3B, a third type of structural member 63 and 65 includes a first flange 67 and a second flange 69. First flange 67 and second flange 69 are merged at a right angle to form an L-shape. First flange 67 has a first end 71 and a second end 73 and a plurality of circular apertures 75 extending longitudinally between first end 71 and second end 73. Each of the circular apertures are spaced an equal distance N apart. First flange 67 further includes a first oblong aperture 77 located at first end 71 of first flange 67, and a second oblong aperture 79 located at second end 73 of first flange 67. First oblong aperture 77 is positioned so as to be perpendicular to second oblong aperture 79. As illustrated in FIG. 3A, the third type of structural member may include one closed end 81 as shown by structural member 63 or have both ends 83 closed as shown by structural member 65. The closed end 81 or 83 may include a third oblong aperture 85.

Second flange 69 includes a first end 87 and a second end 89 with a plurality of circular apertures 91 extending longitudinal between ends 87 and 89. Each of the circular apertures are spaced an equal distance N apart.

The third type of structural member 63 and 65 may be formed from any suitable material including, but not limited to, steel, aluminum, copper, and the like.

Although FIG. 3A shows two different structural members 63 and 65 of the third type, each with the same length, this is not to be construed as limiting the present invention as both longer and shorter lengths have been envisioned.

With reference to FIGS. 4A-4D, and with continuing reference to FIGS. 1A, 1B, 2, 3A and 3B, the structural members of the first type, the second type and the third type may be joined together using fastening members to form a structure. For instance, a shelf 93 can be built using structural members 5, 11, 13, 15, 41, and 43. Fastening members 101 are passed through the circular and oblong apertures to secure the structural members to each other and thereby form a structure. A display stand 95, window box 97, and tool rack 99 may also be formed.

Fastening members 101 may be any suitable fastening member including, but not limited to, bolts and nuts, sheet metal screws, toggle bolts, masonry anchors, and wood screws.

While FIGS. 4A-4D illustrate that the structural members of the present invention may be used to construct a shelf 93, display stand 95, window box 97, and tool rack 99, this is not to be construed as limiting the present invention as the use of the structural members to build a large variety structures has been envisioned.

With reference to FIGS. 5A-5C, and with continuing reference to FIGS. 1A, 1B, 2, 3A, and 3B, a variety of other uses for the structural members have also been envisioned. For instance, with reference to FIG. 5A, a structural member 5 of the first type may be fastened to a table using fastening members 101 to provide additional support to the table. With reference to FIG. 5B, a structural member 7 may be secured underneath a stair to prevent the stair from creaking and to provide additional support to the stair. Also, with reference to FIG. 5C, structural member 15 may be secured to a ceiling using fastening members 101 and used as a rack for hanging clothes.

Throughout this specification reference has been made to circular apertures. However, this is not to be construed as limiting the present invention as other shapes for the apertures have been envisioned. For instance, the apertures may have a square or any other equilateral polygonal shape with more than four edges. Reference has also been made to oblong apertures which have been illustrated as having circular ends. This is also not to be construed as limiting the present invention as other shapes for the oblong apertures have been envisioned. For instance, the oblong apertures may be rectangular having one pair of larger parallel edges and one pair of shorter parallel edges.

While the present invention was described with reference to preferred embodiments of the construction system including perforated modular structural members, those skilled in the art may make modifications and alterations to the present invention without departing from the scope and spirit of the invention. Accordingly, the above detailed description is intended to be illustrative rather than restrictive. The invention is defined by the appended claims, and all changes to the invention that fall within the meaning and range of equivalency of the claims are to be embraced by their scope. 

1. A construction system comprising: structural members of a first type comprising a first flange and a second flange merged at a right angle, each flange including a first end and a second end, the first flange including at least one row of spaced circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end, and the second flange including at least one row of spaced circular apertures extending longitudinally between the first end and the second end; structural members of a second type comprising a single flange including a first end and a second end with at least one row of spaced circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end; and structural members of a third type comprising a first flange and a second flange merged at a right angle, each flange including a first end and a second end with at least one of the ends closed by a web having an aperture, the first flange including at least one row of spaced circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end, and the second flange including at least one row of spaced circular apertures extending longitudinally between the first end and the second end, wherein the structural members of the first type, the second type, and the third type are joinable together using fastening members passed through the circular and oblong apertures to form a structure.
 2. The construction system of claim 1, wherein the oblong apertures are arranged perpendicular to each other.
 3. The construction system of claim 1, wherein the structure is selected from the group consisting of shelves, tool racks, window boxes, and floor stands.
 4. The construction system of claim 1, wherein the fastening members are selected from the group consisting of sheet metal screws, toggle bolts, masonry anchors, and wood screws.
 5. A perforated modular structural member comprising: a first flange; and a second flange merged at a right angle with the first flange, wherein each flange includes a first end and a second end, the first flange includes at least one row of spaced circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end, and the second flange includes at least one row of spaced circular apertures extending longitudinally between the first end and the second end.
 6. The perforated modular structural member of claim 5, wherein the oblong apertures are arranged perpendicular to each other.
 7. A perforated modular structural member comprising: a flange with a first end and a second end with at least one row of spaced circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end.
 8. The perforated modular structural member of claim 7, wherein the first oblong aperture and the second oblong aperture are arranged perpendicular to each other.
 9. A perforated modular structural member comprising: a first flange; and a second flange merged at a right angle with the first flange, wherein each of the flanges includes a first end and a second end with at least one of the ends closed by a web having an aperture, further wherein the first flange includes at least one row of spaced circular apertures extending longitudinally between the first end and the second end, a first oblong aperture at the first end and a second oblong aperture at the second end, and the second flange includes at least one row of spaced circular apertures extending longitudinally between the first end and the second end.
 10. The perforated modular structural member of claim 9, wherein the first oblong aperture and the second oblong aperture are arranged perpendicular to each other. 